Rack assembly for mounting solar modules

ABSTRACT

A rack assembly is provided for mounting solar modules over an underlying body. The rack assembly may include a plurality of rail structures that are arrangeable over the underlying body to form an overall perimeter for the rack assembly. One or more retention structures may be provided with the plurality of rail structures, where each retention structure is configured to support one or more solar modules at a given height above the underlying body. At least some of the plurality of rail structures are adapted to enable individual rail structures o be sealed over the underlying body so as to constrain air flow underneath the solar modules. Additionally, at least one of (i) one or more of the rail structures, or (ii) the one or more retention structures are adjustable so as to adapt the rack assembly to accommodate solar modules of varying forms or dimensions.

PRIORITY APPLICATIONS

This application claims benefit of priority to Provisional U.S. PatentApplication No. 60/643,619, filed Jan. 13, 2005, entitled PV/THERMALINTEGRATED ENERGY SUPPLY SYSTEM, and naming Joshua Reed Plaisted asinventor; the aforementioned application being hereby incorporated byreference in its entirety for all purposes.

This application further is a continuation-in-part of U.S. patentapplication Ser. No. 10/855,254, filed May 26, 2004, entitled MECHANISMFOR MOUNTING SOLAR MODULES, the aforementioned application claimingbenefit of priority to U.S. Patent Application No. 60/544,753, filedFeb. 13, 2004, entitled SYSTEM, METHOD, AND APPARATUS FOR MOUNTING ASOLAR MODULE, and naming Joshua Reed Plaisted as inventor. Both of thepriority applications named in this paragraph are hereby incorporated byreference in their entirety for all purposes.

The U.S. Government has a paid-up license in this invention and theright in limited circumstances to require the patent owner to licenseothers on reasonable terms as provided for by the terms of contract No.NDC-5-55022-01 and contract No. NDO-3-33457-02, both awarded by theDepartment of Energy.

TECHNICAL FIELD

The disclosed embodiments relate generally to the field of solarmodules. In particular, the disclosed embodiments relate to a mechanismfor mounting solar modules to a surface or sub-structure.

BACKGROUND

Modules for converting solar energy into useful forms of energy such asheat and electricity have been around for decades. Because of the sunslow energy intensity and the low conversion efficiency of some solarmodules, a large array of solar modules is often required to service theend-use of the energy. Arrays from several dozen to several thousandsquare feet are common. Moreover, the variety of surfaces on which themodules may be mounted requires a wide range of flexibility andadaptability in the mounting hardware that will be used to structurallyanchor the modules to the surface.

High energy prices and the desire to ‘build green’ have led to increasesin the use of solar photovoltaic (PV) modules to provide electricity andsolar thermal modules to provide heating services for homes and otherbuilding structures. As a parallel development, architects and buildingowners have stressed the need for solar systems that are aestheticallyor functionally integrated into the building facade for improvedaesthetics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of components that combine to form a rackassembly for supporting a solar module, under an embodiment of theinvention.

FIG. 2A illustrates an installed rack assembly that supports a set ofsolar modules over an underlying body, according to one or moreembodiments of the invention.

FIG. 2B illustrates another installed rack assembly that supports a setof solar modules over an underlying body, on which one or more vents areprovided, according to one or more embodiments of the invention

FIG. 3A is a side view of a free rail structure, according to anembodiment of the invention.

FIG. 3B is a side view of a shared rail structure, according to anembodiment of the invention.

FIG. 4A and FIG. 4B are isometric views of a free rail structure and ashared rail structure, respectively, as provided in an installed rackassembly, according to one or more embodiments of the invention.

FIG. 5A and FIG. 5B are side cross-sectional views of a free railstructure and a shared rail structure respectively, as mounted to acommon strut runner, according to one or more embodiments of theinvention.

FIG. 6A and FIG. 6B illustrate an upper rail and a lower rail of a freerail structure, according to one or more embodiments of the invention.

FIG. 7A and FIG. 7B illustrate an upper rail and a lower rail of ashared rail structure, according to one or more embodiments of theinvention.

FIG. 8A is an isometric cross-sectional view of a rack assembly at afirst corner of the overall perimeter, from a perspective of a free railstructures 220, under an embodiment of the invention.

FIG. 8B is an isometric cross-sectional view of the rack assembly at afirst corner of the overall perimeter, from a perspective of one of theshared rail structure, according to an embodiment of the invention

FIG. 9A is top isometric view of a thermal solar panel for use with arack assembly, under an embodiment of the invention.

FIG. 9B is an isometric view of the thermal solar panel shown in FIG.9A, under an embodiment of the invention.

FIG. 9C is a cross-sectional isometric view of the thermal panel shownin FIGS. 9A and 9B, under an embodiment of the invention.

FIG. 9D illustrates a shim plate for use with a thermal solar panel suchas shown and described, under an embodiment of the invention.

FIG. 9E illustrates a frame of a thermal panel such as shown anddescribed, with a set of apertures for receiving a fastener insertedthrough the shim plate, under an embodiment of the invention.

FIG. 10A illustrates an implementation in which a rack assembly isprovided over a series of vents as part of a heat exchange system,according to an embodiment of the invention.

FIG. 10B illustrates an underside of a rack assembly, as implemented inFIG. 10A, under an embodiment of the invention.

FIG. 11A shows a configuration in which a plurality of vents are alignedand provided under one row of a rack assembly on which a solar modulearray is installed, according to an embodiment of the invention.

FIG. 11B shows the formation of an alternative configuration in which amulti-directional channel is formed below a rack assembly, according toan embodiment of the invention.

DETAILED DESCRIPTION

According to an embodiment, a rack assembly is provided for use inmounting solar modules to form a solar array, in which components thatcomprise the rack assembly form at least a partial perimeter seal to theunderlying body. Among other benefits, the perimeter seal enables enablethe capture of heat generated from use of the solar modules for variouspurposes. These purposes may include increasing efficiency ofphotovoltaic cells and heating air. Additionally, the perimeter seal canprovide other uses, such as a cosmetic skirt that further improvesaesthetics by hiding the gap between the array and underlying body. Theperimeter seal can be formed such that it diverts any precipitationrunning down the underlying body from penetrating the underside of thearray. Moreover, any mounting penetrations made under the array isprotected, and the rack assembly with the partial or complete perimeterseal enables a simple covering to be provided under the array if theunderlying body needs to be weatherproofed (i.e. the roof of a house).

Although the deployment of a rack assembly with a sealed or partiallyrestricted perimeter yields aesthetic and weather proofing benefits, italso restricts the flow of air underneath the array. In traditionalinstallations of solar photovoltaic modules, this restriction of airflowis an undesirable effect and may lead to increased module temperaturesand lower conversion efficiencies.

In one embodiment, a rack assembly or mounting system is arranged suchthat the combination of a seamless front surface and perimeter sealingyields air channels underneath the array of solar modules. The creationof these air channels allows for the heat generated by the solar modulesto be captured and removed to increase their conversion efficiency andcreate a useable energy stream. The system may also employ solar thermalmodules that act to further boost the air temperature, leaving the arrayfor use in cold climates or other instances in which higher air streamtemperatures are required.

According to an embodiment, a rack assembly is provided for mountingsolar modules over an underlying body. The rack assembly may include aplurality of rail structures that are arrangeable over the underlyingbody to form an overall perimeter for the rack assembly. One or moreretention structures may be provided with the plurality of railstructures, where each retention structure is configured to support oneor more solar modules at a given height above the underlying body. Atleast some of the plurality of rail structures are adapted to enableindividual rail structures to be sealed over the underlying body so asto constrain air flow underneath the solar modules. Additionally, atleast one of (i) one or more of the rail structures, or (ii) the one ormore retention structures are adjustable so as to adapt the rackassembly to accommodate solar modules of varying forms, dimensions orinstallation height or spacing requirements.

According to an embodiment, the rack assembly may include couplingstructures that enable the rack assembly to be sealed over theunderlying body. In an embodiment, the coupling structures are in theform of a flashing component, or a combination of flashing components.According to one embodiment, the combination of flashing componentsinclude a first or lower flashing component that enable a seal to beformed with the underlying body, and a counter flashing component thatoverlays where the lower flashing component joins the rack assembly.

In an embodiment, the retention structures are in the form of anextended member and an underlying or lower shelf. The retentionstructure enables retention of a solar module when a compressive forceis applied to the extended member.

According to another embodiment, a rack assembly is provided formounting solar modules over an underlying body. The rack assembly may beinstalled over an underlying body and include a plurality of railstructures that are arranged to form an overall perimeter. One or moreretention structures may be provided with the plurality of railstructures to support one or more solar modules mounted therein at agiven height over the underlying body. At least some of the plurality ofrail structures are sealed over the underlying body so that at least aportion of the overall perimeter is closed. A channel may be formed atleast in part by the at least some of the portion of the overallperimeter that is sealed over the underlying body and occupies at leasta portion of the given height separating the one or more solar modulesfrom the underlying structure.

Under another embodiment, a solar energy transfer system is providedover an underlying body. The system includes a plurality of solarmodules that receive solar energy and convert the solar energy intoelectricity or heat. The plurality of solar modules may be of a givensize that is within a range of possible sizes that can be handled by therack assembly. A rack assembly supports the plurality of solar modules agiven height over an underlying body. The rack assembly may be sealedacross at least a portion of its perimeter to the underlying body todefine, at least in part, one or more channels underneath the pluralityof solar modules that constrains air flow. Additionally, the rackassembly is cooperatively positioned with an air driver to enable theair driver to direct air through the one or more channels so that theair is heated by heat from one or more of the plurality of solarmodules.

As an example, FIG. 10A and FIG. 10B illustrate a rack assembly that iscooperatively engaged with an air driver, which may be provided throughuse of a vent. In particular, a vent may be provided underneath the rackassembly and be coupled to, for example, a fan for drawing air.Alternatively, the vent may blow air from one location to anotherunderneath a rack assembly such as described by one or more embodiments.

Under another embodiment, a rack assembly includes a plurality of railstructures and a plurality of retention structures. The plurality ofretention structures may be provided by the plurality of railstructures. In an embodiment, one or more of the plurality of retentionstructures are adjustable between adjacent rail structures in order to(i) loosely grasp and hold a given solar module to enable manualadjustment of the positioning and securement of the given solar module,(ii) mechanically secure and hold the given solar module in an installedposition a given height over the underlying body.

Overview

FIG. 1 is a simplified illustration of a rack assembly for supportingsolar modules, under one or more embodiments of the invention. As shown,a rack assembly 10 includes a plurality of rail structures 12 thatprovide support for individual solar modules 14. When installed, therail structures 12 support the individual solar modules 14 a givenheight h above an underlying body 15. The underlying body 15 maycorrespond to any surface, platform or structure on which solar modules14 are mounted. For example, underlying body 15 may correspond to arooftop of a commercial or residential building. The solar modules 14may correspond to photovoltaic solar cells that convert solar energyinto electricity, or alternatively, solar heating modules which directlygenerate heat using solar energy.

According to one or more embodiments, the rail structures 12 areadjustable pair-wise, or in other combinations, in order to hold inplace solar modules 14 of various dimensions and sizes. In oneembodiment, the solar modules 14 are supported by a combination ofretention structures 16. Each retention structure 16 may be providedwith a corresponding one of the rail structures 12. In one embodiment,each retention structure 16 is a structural feature of the correspondingrail structure 12. For example, each rail structure 12 may comprise ofmultiple interconnected segments, and the retention structure(s) may beone of the interconnected elements. Alternatively, the retentionstructures 16 may be integrated or unitarily formed with the individualrail structures 12. Each retention structure 16 supports individualsolar modules 14 by grasping edge segments. In one embodiment, theretention structures 16 and/or rail structures 12 are adjustable tograsp and support solar modules 14 of varying thicknesses and forms.

As shown by FIG. 1, an embodiment provides that rail structures 12 aremounted indirectly to the underlying body 15 through use of a set ofstrut runners 18. Each strut runner 18 mounts to the underlying body 15and to multiple rail structures 12, thus providing lateral support tomaintaining the rail structures 12 upright, while at the same timeproviding a buffer between the individual rail structures 12 and theunderlying body 15. The rail structures 12 may mount to the strutrunners 18, and the strut runners may mount to the underlying body 15.

According to an embodiment, the rack assembly 10 forms a portion of asolar heat exchange system that uses heat generated from the solarmodules 14 for any one of various useful purposes. The heat exchange maybe enabled by the formation of one or more channels 20 between anunderside of solar modules 14 and the underlying body 15. An individualchannel 20 may be defined in part by one or more of the rail structures12, as well as the underlying body and possibly the underside of thesolar modules 14. The individual channel 20 may occupy at least aportion of the thickness defined by the height h. The solar heatexchange system may further include other components, such as thermalpanels 910 (FIG. 9A), as well as air directors that draw air into thechannel 20, and/or push the air through the channel. When installed aspart of a solar heat exchange system, the rack assembly 10 may bepositioned to supply heated air to such air directors, and to beproximate to the environment that is to receive or use the heated air.For example, the rack assembly 10 may be installed on the rooftop of adwelling, and also direct heated air into a vent or air circulationsystem of the dwelling as part of its ability to heat air in the channel20.

Useful purposes for generating heat from the solar modules 14 mayinclude, for example, any one or more of the following: (i) cooling theindividual solar modules 14 (when photovoltaic) so as to make them moreefficient, (ii) pulling air from the environment underneath the solarmodules 14 for purpose of heating the air for another closed environmentor system (e.g. for a house), and (iii) circulating air from the closedenvironment or system underneath the solar modules 14 to heat that airand use it for heat.

Installed Rack Assembly

FIG. 2A illustrates an installed rack assembly 110 that supports a setof solar modules 114 over an underlying body 115. The rack assembly 110may be structured and adapted to include features such as described withone or more embodiments of the invention. The underlying body 115 maycorrespond to, for example, a rooftop or roof structure of a building ordwelling. In general, the underlying body 115 may correspond to anyarea, surface or platform that can receive sunlight and be connected toa building, place or location that can use the solar energy.

Embodiments of the invention contemplate that different types of solarmodules 114 may be employed in various implementations and context. Forexample, as shown by FIG. 2A, the solar modules 114 include photovoltaicmodules 124 and thermal modules 125. Under one embodiment, the perimetermay include one or more sealed lengths 132 and an open length 134 fromwhich air from the environment is drawn. As will be described, channels(not shown in FIG. 2A) may be provided between the rack assembly 110 andunderlying body 115 for purpose of constraining airflow. Air drivers(not show in FIG. 2A) may drive (e.g. push or pull) air within theformed channels. The solar modules 114 generate heat, either throughdesign or as an inherent by-product. According to one or moreembodiments, this heat warms the air as it is drawn from the environmentand pulled through the channels formed underneath the solar modules 114.

Numerous alternatives and variations are contemplated. For example, allof the perimeter of the rack assembly 110 may be sealed, and air maydrawn from within a dwelling on which the rack assembly 110 is provided.This air may be pushed through channels, then back into the dwellingwhen warmed. Alternatively, some or all of the open length 134 may besealed, or conversely, portions of the sealed lengths 132 may be openedor perforated as part of an underlying channel system.

FIG. 2A illustrates one implementation in which heated air is directedinto a duct 140 within a structure of the underlying body 115. Forexample, warm air may heat a dwelling on which the rack assembly 110 isinstalled, and the duct 140 enables the heated air to flow into thecirculation system of the dwelling.

As mentioned, the solar modules 114 may be formed by a combination ofthe photovoltaic modules 124 and the thermal modules 125. Thephotovoltaic modules 124 can generate some residual heat when receivingsolar energy and converting the solar energy into electrical current. Incontrast, the thermal modules 125 may directly convert the solar energyinto heat at a higher efficiency. The use and number of thermal modules125 may depend on the use of the heated airflow, as well as theenvironment where the rack assembly 110 is installed. For example, whenthe purpose of heating air in the channels is to supply warm air to adwelling of the underlying body 115, the thermal modules 125 have moreuse in colder environments, while warm environments may require only useof photovoltaic modules 124. Even in cold environments, thermal modules125 may be used to convert solar energy into hot air due to the highoperating efficiency achieved by their designs, and additionalcomponents may be used to drive the hot air into the dwelling.

FIG. 2B illustrates a variation similar to an embodiment such as shownin FIG. 2A, in that multiple ventilation outlets 150 may be employed fordirecting heated air from under the rack assembly. As such, theventilation outlets are located underneath the thermal modules 125. Asshown with FIG. 2A, the open length 134 of the perimeter is provided onone side, and the series of vents 150 are provided lengthwise on theother side of the perimeter formed by the rack assembly 110. Forexample, the vents 150 may guide the directed heated air inward into thestructure of the underlying body 115.

Rail Structure

According to one or more embodiments, one of the overall primarystructural elements of the overall rack assembly is a rail structure.Rail structures are elements that provide primary support to the solarmodules, thus, for example, enabling the solar modules to be oriented toreceive solar energy, while at the same time being securely fixed toresist wind and other forces. Under one embodiment, two types of railstructures may be provided. A free rail structure 220 supports solarmodules 114 on one lateral side (left-right in the paper), so as to forma portion of the overall perimeter of the rack assembly 110 (FIG. 1) onits other side. Such a rail structure is shown and described with FIG.3A. In contrast, a shared rail structure 240 (FIG. 3B) provides interiorsupport, and supports solar modules on both a left side or a right side,so that it is shared by more than one solar module. Such a railstructure is shown and described by FIG. 3B. As will be described, eachrail structure 220, 240 is adjustable to support solar modules 114 ofvarying sizes. Furthermore, embodiments provide that the rail structures220, 240 may be configured to loosely grasp solar modules 114, beforebeing adjusted to clamp down onto the solar modules. Among otherbenefits, this feature of the free and shared rail structures 220, 240enables all of the solar modules to be placed in position before theindividual rail structures 220, 240 are clamped down to affix the solarmodules 114 as a set in the installed position. As will be described,one or more embodiments provide that the rail structures 220, 240 andassociated features and structural elements may be used to implement arack assembly, such as described with FIG. 1, FIG. 2A, FIG. 2B andelsewhere described in this application.

According to one or more embodiment, such as shown by FIG. 3A and FIG.3B, each rail structure 220, 240 has an interleaved assembly structurethat can be (i) adjusted to loosely grip or retain individual solarmodules 114, and (ii) compressed to clamp down on solar modules 114 andhold them in a fixed position. With reference to FIG. 3A, the free railstructure 220 supports a corresponding solar module 114 on one side,while forming a perimeter support of an overall rack assembly. Under oneembodiment, the free rail structure 220 is a multi-piece element thatcan grasp and support an individual solar module from its edge section.Each solar module 114 has its own frame 235 on which an individual solarpanel 214 (photovoltaic laminate or thermal glazing and absorberassembly) is supported in planar fashion. According to one embodiment,free rail structure 220 is adjustable to accommodate and grasp frameshaving any thickness t within a range T.

The interleaved construction of the free rail structure 220 includes alower rail 226 and an upper rail 228. The upper rail 228 may be movedinward within the confines of lower rail 226, enabling an overall heightof the free rail structure 220 to be contracted. Under oneimplementation, the inward movement of the upper rail 228 may beaffected by a compression mechanism. In an embodiment, the compressionmechanism, is in the form of a compression bolt 225, which enters a topsurface 227 of upper rail 228 via a hole or slot. The bolt 225 may betightened within the opening by threading into fastener 237 located onthe lower rail 226, so as to cause the upper rail to move inward intothe lower rail 226. A washer 223 may buffer the bolt 225 when it iscompressed. The bolt 225 may be of sufficient length to extend through afloor 229 of the upper rail 228 and into an interior of the lower rail226. However, under one embodiment, the length of the bolt 225 is not solong as to cause the bolt 225 to extend through a floor 227 of the lowerrail 226. The range of T may be dependent on one or more of the size ofthe compression bolt 225, and the amount that the upper rail 228 can bepushed into the lower rail 226.

In order to hold individual solar modules 114 captive, each free andshared rail structure 220, 240 may include one or more retentionstructures 245, 265. The retention structures may grasp on to an edgesection of the frame 235 for an individual solar module 114. In anembodiment, the retention structure 245 is in the form of a lower shelf244 and an upper extension 243. When the bolt 225 is clamped down, theupper rail 228 is moved inward into the confines of the lower rail 226,causing the upper extension to press the frame 235 of the solar module114 against the lower shelf 244. An overall movement of the upper rail228 is shown by A. The resulting force affixes that edge section of thesolar module 114 with the rail structure 220. The solar module 114 maybe installed when the free and shared rail structures 220, 240 aresecured to the underlying body. As will be described, the securement ofthe solar modules 114 to the underlying body may include one or morestrut runners 450 (see FIG. 4A and FIG. 4B), which may be used tointerconnect the free rail structure 220 and the shared rail structure240 to the to the underlying body, as well as to each other. However,use of strut runners is a design implementation, as alternatives arecontemplated. For example, as an alternative or addition, each of therail structures 220, 240 may be secured directly to the underlyingstructure.

According to an embodiment, some or all of that free rail structure 220is sealed over the underlying body on which the rack assembly 110 ismounted. In particular, one embodiment provides that free rail structure220 is sufficiently sealed to confine the flow of air within a channelor other boundary defined by the rail structure. In one embodiment, freerail structure 220 is used with one or more flashing features orcomponents, which may be combined with other sealants or materials inorder to effectuate a seal of the rail structure 220 over the underlyingbody. In an embodiment shown by FIG. 3A, one of the flashing features ismade integral to the rail structure 220. An overlaying or upper flashingcomponent 255 may extend laterally and downward from relative to theexterior side 249 of the free rail structure 220. The purpose of theoverlaying flashing component 255 is to overlay an underlying flashingcomponent (not shown in FIG. 3A), which may be installed separately fromthe free rail structure. In this way, the upper flashing component 255may be considered a counter flashing. Additional details on the flashingarrangement is described in greater detail, including with FIG. 4A.

It is possible for the application of the compression on the upper rail228 to cause an unwanted moment, particularly to bend the upper rail 228outward, away from the solar module 114. To counter this unwantedmoment, a shim plate 270 may be provided to support the exterior side249 from application of the compression force (which may be brought onby the compression bolt 225). The shim plate 270 may be formed fromrigid and strong material, such as metal, and made to be adjustable inheight relative to the free rail structure 220, to accommodate thevarying height t of the rail structure. The shim plate 270 may bepositioned so its top edge is provided just under the upper flashingcomponent 255. One or more threaded fasteners 239 (e.g. screws) may beused to secure the vertical position of the shim plate 270 in the lowerrail 226. Due to the localized nature of the compression force beingresisted, the shim plate need not span the length of the rail structure220. Individual shim plates 270 may be employed in proximate location toone or more compression bolts 225 along the rail structure 220. Further,alternative structures, features or means may be used instead of theshim plate 270 to achieve the same effect.

FIG. 3B illustrates the shared rail structure 240 that is locatedinternal to perimeter of the rack assembly 110, according to anembodiment. The shared rail structure 240 may have similar constructionas the free rail structure 220 (FIG. 3A), in that it may include a lowerrail 246 and an upper rail 248, with the upper rail being able to becompressed and moved inwards within confines of lower rail 246. Thedirectional arrow A illustrates the movement of the upper rail 248within the lower rail 246. A compression mechanism may compress theupper rail 248. As with the free rail structure 220, the shared railstructure 240 includes retention structures 265 for holding solarmodules 114. However, the shared rail structure 240 may includeretention structures 265 on opposing lateral sides 261, 263, rather thanjust one side (as is the case with the free rail structure 220). Eachretention structure 265 may include a lower shelf 266 and an upperextension 268, similar to corresponding features on the free railstructure, for enabling the grasping of frames 235 of individual solarmodules 114. According to one embodiment, the compression mechanism maybe in the form of a compression bolt 295, which can be tightened inwardby threading into a fastener 247 located on the lower rail so as tocompress the upper rail 248. Tightening of the compression bolt 295causes the upper extensions 268 to press corresponding solar moduleframes 235 against the lower shelves 266.

In use, an embodiment such as shown provides for the shared railstructure 240 to support a pair of solar modules 114, with one solarmodule on each side. As with the free rail structure 220, each solarmodule may be gripped and supported from its perimeter or near itsperimeter section, using the frame 235 of the solar module. An opposingperimeter of each solar module 114 may be held by either one of the freerail structures 220, or another one of the shared rail structures 240.The use of the compression mechanism and the retention structure 265enables the shared rail structures 240 to loosely grip solar modules 114in position before application of the compression force that affixes theindividual solar modules in an installed position. In connection withthe free rail structure 220 that can be adjusted in similar fashion,solar modules 114 may be loosely placed in clusters and affixed at onetime, saving time, energy and improving the results of the installation.

FIG. 4A and FIG. 4B are isometric views of a free rail structure 220 andshared rail structure 240, respectively, as provided in an installedrack assembly, according to one or more embodiments of the invention. InFIG. 4A, free rail structure 220 is installed on the underlying body 215through a strut runner 450. The free rail structure 220 is also sealedover the underlying body 215, so as to form a portion of one of theclosed lengths 134 (FIG. 2A) of the overall perimeter. When installed,free rail structure 220 retains solar module 114 by grasping the solarmodules frame 235 using retention structure 245 formed by thecombination of upper extension 243 and lower shelf 241. In thecompressed state, the bolt 225 extends through upper rail 228 and intolower rail 226. The entire rail structure 220 is secured to underlyingstrut runner 450, which in an implementation shown, extends orthogonalacross the underlying body 215 relative to the direction of the freerail structures 220. In this way, each strut runner 450 may interconnectat least one free rail structure 220 with a shared rail structure 240 oranother free rail structure 220. One implementation provides that eachstrut runner 450 extends across the entire rack assembly 110 (FIG. 2A),so as to interconnect each free and shared rail structure 220, 240. Thestrut runner 450 may include a slot 452 for receiving a threadedfastener, such as a bolt 456 passing through a clip 458. This bolt 456and clip 458 may slide along slot 452. Clip 458 may include a mountingedge 459 that can be forced into a friction fit within a correspondinggroove formation 462 on the lower rail 226 of the free rail structure220. In one implementation, the mounting edge 459 may be placed withinthe corresponding groove formation 462 and compressed to remain coupledtherein by application of bolt 456. In this way, rail structure 220 issecured to the strut runner 450. The strut runner 450 may be secured tothe underlying body 215 through traditional fasteners, such as screwsand bolts, but numerous other means are possible, such as adhesives oran engaged fit within the underlying body 215, or a combination thereof.When installed, the free rail structure 220 sits over the strut runner450, so that in between adjacent strut runner's 450, a gap is formedbetween the underlying body 215 and the floor 227 of the lower rail 226.

In order to seal the free rail structure 220 to the underlying body 215,flashing components may be used. A lower flashing component 455 mayextend a thickness into the underlying body (e.g. under the roofingmaterial of the underlying body 215) and bend upward to be mated againsta lower external side 445 of the rail structure 220. In one embodiment,the shim plate 270 is provided between the lower flashing component 455and the lower external side 445. The lower flashing component 455 mayinclude sealants to effect a seal with the underlying body 215, as wellas with the lower external side 445 of the rail structure 220. The upperflashing component 255 may extend outward from the external side of therail structure 220 then downward, so as to overlay the lower flashingcomponent 455, and in particular, the joining of the lower flashingcomponent to the lower external side 445 (or to the shim plate 270) ofthe rail structure 220. In an embodiment such as shown by FIG. 4A, thecombination of the upper and lower flashing components 455, 255 enablethe free rail structure 220 to be sealed over the underlying body 215while being supported by the strut runner 450. As will be explained ingreater detail, the sealed free rail structure 220 enables formation ofthe closed lengths 132 (FIG. 2A), and as such, enables the formation ofchannels underneath the solar modules 114.

FIG. 4B is an isometric view of the shared rail structure 240, for usewith the rack assembly 110 (FIG. 1), according to an embodiment of theinvention. The shared rail structure 240 may share the strut runner 450with one or more free or shared rail structures 220, 240. As described,the strut runner 450 includes a pair of coupling mechanism 485, havingcomponents similar to the coupling mechanism 475 of the free railstructure 220 in FIG. 4A. As such, each coupling mechanism 485 maycomprise of the slot 452 in which the bolt 456 and the clip 458 areprovided. As such, one such bolt 456 and clip 458 may be provided oneach lateral side of the free rail structure 240. With shared railstructure 240, grooved formations 472, 472 may be provided on eachlateral side of the lower rail 226 of the free rail structure 220. Eachof the grooved formations 472, 472 may receive the mounting edge 459 ofthe clip 458 provided on the respective side of the shared railstructure 240. Thus, the shared rail structure 240 may havesubstantially similar construction with the free rail structure 220,with the exception that since no lateral side of the shared railstructure is external, the additional grooved formation 472 is providedinstead of any flashing components.

On each lateral side of the shared rail structure 240, the upperextension 268 and lower shelf 266 comprise the retention feature 265that supports the frame 235 of the corresponding solar module 114. Thecompression bolt 295 may insert and compress the upper rail 248 to moveinward into the lower rail 246 and direct the respective upper extension268 and lower shelf 266 to support the frame 235 of the solar module114.

Since no external side is provided, an embodiment provides that theshared rail structure 240 is not sealed over the underlying body 215.Rather, an embodiment provides that the shared rail structure 240 to beraised by the strut runner 450 and provide vertical support to the solarmodules 114. However, alternative implementations and designs may beused, such as to the relationship of the shared rail structure 240 withthe underlying body 215. For example, in one implementation, a windingchannel arrangement may be formed under a given rack assembly 110 (FIG.2A), in part through the formation of barriers formed by sealing theshared rail structures 240 to the underlying body.

Embodiments described herein illustrate use of inherent structuralsurfaces to form channels for constraining airflow, under an embodimentof the invention. In FIG. 4A, the channel may be formed by an interiorsurface of the lower flashing component 455, as well as by an undersideof the solar panel 214 or module 114, and the rail structure 220. In oneimplementation, the shared rail structure 240 may be raised so thatairflow is constrained underneath it. Alternatively, ducts or othermaterials may be provided in the spacing under the rack assembly 110 toform bends and paths for the airflow.

FIG. 5A and FIG. 5B are side cross-sectional views of the free railstructure 220 and the shared rail structure 240 respectively, as mountedto the common strut runner 450. In FIG. 5A, free rail structure 220 ismounted to a peripheral section 552 of the strut runner 450. Inpractice, an array or arrangement of solar modules 114 may requiremultiple strut runners 450 coupling multiple rail structures 220, 240.In an embodiment such as shown, the strut runner 450 includes the slot452 extending its length for receiving threaded fasteners from mountedrail structures 220, 240. The coupling mechanism 475 includes a nut 556and bolt 456 with clip 458 that mounts the free rail structure 220 tothe strut runner 450. The strut runner 450 may be hollow so that nut 556may secure each bolt 456 in place to prevent lateral movement (left toright in the paper) across the length of the strut runner 450, as wellas removal of the bolt from the slot 452. The mounting of the free railstructure 220 may include insertion of the mounting edge 459 into thegroove formation 462 on the inward lateral side of the free railstructure 220.

As shown in FIG. 5A and FIG. 5B, the individual solar modules 114supported by the rail structures are planar in their positioning overthe rail structures 220, 240, which provide the vertical support withthe retention structures. The compression bolt 225 of the rail structure220 may, when compressed, extend through upper rail 228 into the lowerrail 226, but stop short of penetrating or contacting the strut runner450.

As shown by FIG. 5A, the shim plate 270 is mounted to the exterior sideof the rail structure 220. The fastener 239 inserts into the shim plate270 to maintain the shim plate in an upright position at a desiredheight. In this way, the shim plate 270 provides support againstunwanted movement, directed to the free end of the rail structure 220.The upper flashing component 255 extends outward from the rail structureso as to partially overlay the shim plate 270, and the lower flashingcomponent when it is sealed to the shim plate 270 and/or exterior sideof the rail structure 220.

With regard to FIG. 5B, shared rail structure 240 supports a pair ofsolar modules 114, 114, with one solar module provided on each lateralside of that rail structure. Under one embodiment, a single strut runner450 may extend across the underlying surface 215 (not shown in FIG. 5B)and support a row of free rail structures 220 (FIG. 5 a) and shared railstructures 240. The strut runner 450 may be secured to the underlyingbody 215 at various points, using, for example, screws, adhesives orother coupling mechanisms.

As with the free rail structure, the compression bolt 295 may compressthe upper rail 248 within the lower rail 246, while not contacting orpenetrating the strut runner 450. The lower rail 246 of the shared railstructure 240 includes the grooved formations 472, 472 on each lateralside. Each coupling mechanism 485, 485 includes the mounting edge 459 orother member to insert into the respective groove formation 472, 472 inorder to secure the shared rail structure 240 to the strut runner 450.According to an embodiment, each coupling structure 485, 485 may operateto secure to the strut runner 450 and to the respective grooveformations 472, 472 to secure each shared rail structure from one of thetwo lateral sides.

Rail Structure Components

FIG. 6A and FIG. 6B illustrate the upper rail 228 and lower rail 226 ofthe free rail structure 220, according to one or more embodiments of theinvention. In an embodiment such as shown, the free rail structure 220(FIG. 3A and FIG. 4A) is a multi-piece component, although otherembodiments contemplate a more unitary construction. In FIG. 6A, theupper rail 228 is shown with the upper flashing component 255. The upperflashing component 255 provides a counter flash to the installed lowerflashing component 455 (FIG. 4A). In this way, the upper flashingcomponent 255 serves to shield the merger of the lower flashingcomponent 455 with the exterior surface of the free rail structure 220.A rail segment 610 of the upper rail is dimensioned to allow insertionof that section and movement of the upper rail 228 within the lower rail226 (FIG. 6B), at least to an extent to accommodate the range T (FIG.3A).

While in FIG. 6A, the upper flashing component 255 is shown to be aunitary member of the rail structure (formed, for example, through aprocess of metallurgically shaping), other embodiments andimplementations consider the upper flashing component (if provided) tobe an attached or assembled component.

In FIG. 6B, the lower rail 226 is provided having a receiving segment612 and a base 618. The receiving segment 612 is open to receive therail segment 610 of the upper rail 228. In one embodiment, a dimensionof the opening of the receiving segment 612 is slightly greater than thedimension of the rail segment 610 of the upper rail 228. This allowsinsertion of the rail segment 610.

With reference to FIGS. 6A and 6B, each of the upper rail 228 and lowerrail 226 combine to form and provide part of the overall retentionfeature 245 (FIG. 4A). In an embodiment, the upper extension 243 isprovided in the form of a flange member or extension from a top (or neartop) surface of the upper rail 228. The lower shelf 241 is formed by thebase 618 having a greater dimension than the receiving segment 612, sothat the lower shelf 241 forms. As such, the lower shelf may, under oneembodiment, be part of the lower rail 226.

With further reference to FIG. 6B, the lower rail 226 may include, as anintegral or unitary feature, groove formation 462 for receiving themounting component 475 (FIG. 4A). Additionally, engagement openings 622for receiving threaded or other coupling members for purpose of enablingan end cap (not shown) to be coupled and secured to the end of the lowerrail 226. In an implementation, the engagement openings 622 are providedon diametric corners of the base 618 of the lower rail 226. The end capsprovide decorative features, as well as the retention of solar modules114 during assembly.

FIG. 7A and FIG. 7B illustrate the upper rail 248 and lower rail 246 ofthe shared rail structure 240, under one or more embodiments of theinvention. In FIG. 7A, the upper rail 248 is similar to that of the freerail structure 220, except that two upper extensions 243 are extendedlaterally in opposite directions. The two upper extensions 243 formportions of the overall retention feature 265, which is provided on eachside to separately grip and support different solar modules 114.

Likewise, in FIG. 7B, the base 718 provides separate lower shelves 246,each for receiving and vertically supporting the frame 235 (FIG. 3A) ofthe solar modules when compression occurs. At the bottom of the base718, grooved formations 472 (FIG. 4B) are provided on each lateral sidefor purpose of receiving the engagement ends 459 of correspondingcoupling structures. As with the free rail structure 220, one or moreengagement openings 744 may be provided to receive end caps similar tothose of free rails 220. In contrast to an embodiment such as shown inFIG. 6B, the engagement openings are provided at the top of the base718, to accommodate opposing groove formations 472 that couple the railstructure to a corresponding one of the strut runners 450.

End Segment Construction

In an embodiment such as shown above, a direction in which the free railstructure 220 extends provides one perimeter dimension of the overallrack assembly 110 (FIG. 2A and FIG. 2B). Another dimension may beprovided by of the strut runner 450, or other interconnecting membersthat extend between free and shared rail structures 220, 240. Under oneor more embodiments of the invention, structures for capping and sealingthe rack assembly on the perimeter in an overall direction of the strutrunners 450 are referred to as end segments. In order to create channelsthrough sealing lengths of the overall perimeter of the rack assembly,an embodiment provides that one or both of the end segments (assuming arectangular configuration) are sealed in whole or in part to theunderlying body on which the rack assembly is provided.

FIG. 8A is an isometric cross-sectional view of the rack assembly at afirst corner of the overall perimeter, from a perspective of one of thefree rail structures 220, under an embodiment of the invention. Asshown, the free rail structure 220 extends along the perimeter andterminates at an end segment. The end segment may include a cap strip860 having a horizontal segment 862 and a vertical segment 864 (FIG.8B). A compression mechanism may force the cap strip 860 to stay fixedwith respect to the solar module 114. In FIG. 8A and FIG. 8B, theappearance and construction of the solar module may differ because itillustrates solar modules that are thermal modules, as opposed tophotovoltaic in nature (as described elsewhere in this application).

In one embodiment, installation of the cap strip 860 followsinstallation of the remainder of the rack assembly 110 (FIG. 2A and FIG.2B). When the remainder of the rack assembly 10 is affixed, acompression screw 855 is placed through an opening of the horizontalsegment 862 to direct the cap strip into a fixed position relative tothe free rail structure 220.

In an embodiment, an end cap 875 may be used to enclose the open end ofthe cap strip 860 to shield the mating surface of the free railstructure 220 and cap strip 860 from the entry of precipitation. A screwboss 858 (FIG. 8B) of the cap strip 860 may provide an opening forinsertion of a fastener to maintain the end cap 875 in place.

FIG. 8B is an isometric cross-sectional view of the rack assembly at afirst corner of the overall perimeter, from a perspective of one of theshared rail structure 240, under an embodiment of the invention. Asshown, the horizontal segment 862 of the cap strip 860 is secured overthe frame 235 of the solar module 114. The compression bolt 855 securesthe cap strip 860 onto the free rail structure 220, so as to overlay thefree rail structure 220 and shared rail structure 240 (not shown).

FIG. 8B illustrates that in an implementation in which the lengthprovided by the cap strip 860 is to be sealed, an embodiment providesthat a combination of flashing components may be used. As with the freerail structure 220, an embodiment may provide for a flashing andcounter-flashing combination to enable the cap strip 860 to be sealedover the underlying body. The seal may promote formation of channelsthat hear air drawn from the environment or other source.

According to an embodiment, the counter-flashing combination may includea lower flashing component 845 that overlays, embeds or otherwise sealsonto or against the underlying body 215. The lower flashing component845 may bend from a horizontal segment provided over the underlying bodyinto to upright position just beneath the cap strip 860. The cap strip860 overlays the lower flashing component 845 with its horizontalsegment 862 from the top, and its vertical segment from behind, so thatthe two components form the flashing and counter-flashing combination.

According to an further possible embodiment, an intermediary sealingshelf 880 may be utilized to assist the sealing on the end segments.Depending on the tolerances used in the construction of the rackassembly 110, a gap may be formed between the module frame 235 andflashing component 845, which is effectively bridged by the sealingshelf 880. Although the sealing shelf 880 is shown as a separateelement, it may be incorporated as a unitary feature on the solarmodules 114 or members of the rack assembly 110.

Thermal Modules

As mentioned with embodiments such as described with FIG. 2A and FIG.2B, solar modules 114 can refer to either modules that primarilygenerate electricity or heat. When solar modules are designed toprimarily generate heat, but not electricity, such modules are referredto as thermal modules. Thermal modules may be constructed to includefeatures and components that are different than photovoltaic modules. Assuch, the thermal modules have different dimension (thickness inparticular) and structure, unless such panels are altered duringinstallation.

In order to accommodate thermal modules with photovoltaic modules, oneembodiment provides that the thermal modules are made adjustable inthickness (“effective thickness”) to match the configuration of the rackassembly for accommodating the thickness and structural variations ofthe photovoltaic modules. Accordingly, one or more embodiments providefor the use of thermal modules on a rack assembly that also includesphotovoltaic modules. According to one embodiment, the rack assembly 110(FIG. 2A and FIG. 2B) can include solar modules 114 that providephotovoltaic or thermal properties. As will be described, the differentsolar modules have different dimensions and structural features, and assuch, require different settings and/or adaptations from retentionfeatures 245, 265 (FIG. 3A and FIG. 3B) that grasp the respectivemodules. For example, the retention features 245, 265 may be adjustableto alter a dimension for gripping solar modules after the given heightin which the modules are to be raised from the underlying body has beenset. Among other uses and benefits, embodiments of the invention enablethe rack assembly 110 to accommodate and grasp different kinds of solarmodules 114 through adjustments to rail structures and other membersthat retain such solar modules. Additionally, solar modules may be madeto be adjustable in their effective thickness to enable the rackassembly to be uniformly configured for all solar modules.

FIG. 9A is top isometric view of a thermal solar panel 910, according toan embodiment. The thermal solar panel 910 may correspond to or formpart of one of the solar modules 114 provided on the rack assembly 110,such as shown in FIG. 2A and FIG. 2B. Accordingly, the thermal solarpanel 910 may include a translucent or clear material layer 916, such asa glass sheet or other clear structure to receive solar rays. A shimplate 915 is provided on one or more lateral sides of the solar panel910. As will be described, the shim plate 915 enables adjustment of therack assembly 110 and positioning of the solar module 114 on which thethermal panel 910 is provided. A frame-wall 908 and spaced ribs 912provide structural support for the thermal panel 910.

FIG. 9B is an isometric view of the thermal solar panel 910, with theclear material layer 916 (FIG. 9A) removed, under an embodiment of theinvention. An absorption layer 922 is provided underneath the materiallayer 916 to absorb solar energy from rays that pass through thematerial layer. The absorption layer 922 may be designed to promoteabsorption, through use of material and coloring. In one embodiment, theabsorption layer 922 is formed from a metal, such as aluminum or copper,and painted black.

FIG. 9C is a cross-sectional isometric view of the thermal panel 910,under an embodiment. The thermal panel 910 includes a frame 935, whichforms a perimeter of the material layer 916 and the absorption layer922. The frame 935 includes a grasp 928 that retains the clear materiallayer 916. Deformable or protective spacers 929 may be provided withinthe grasp 928 to cushion the clear material layer 916 while it is heldin position. In one implementation, the absorption layer 922 may includeupturns 932 for added surface area and support.

In an embodiment, the thermal panel 910 includes a shim plate 915 thatenables the panel to be included in the rack assembly in which othersolar modules of other thicknesses are provided. The shim plate 915 maybe moved vertically to increase or decrease the effective height of thethermal panel 910. In one implementation, the effective thickness isincreased when the shim plate 915 that may be adjusted to protrude fromthe base 921 of the thermal panel. When the shim plate 915 is raised tobe flushed, the effective thickness is at its minimum. As such, thethickness of the thermal panel 910 may be adjusted so that the effectivethickness (as provided by the shim plate 915) matches, or substantiallymatches the thickness of other solar modules. For example, the thicknessof the thermal panel 910 may be within 20% of the thickness of the solarmodules 114 through vertical adjustment of the shim plate 915, whilewithout the adjustment, the thickness would be off by more that 80%. Thelesser the difference between the thickness of the thermal panel 910 andother solar modules 114, the better the seal and resulting air channelsthat can be formed under the rack assembly. Further, the uniformthickness provides a better assembled structure that is more stable,less likely to be under stress, and more aesthetic.

FIG. 9D illustrates the shim plate 915. The shim plate 915 maycorrespond to a flat rigid bar, such as formed by aluminum, having setsof connectivity apertures 925, 925. The connectivity apertures 925 maybe provided in pairs 926, with each pair being at a different verticalposition on the shim plate 915. The different vertical positions of thepairs 926 enable variation in the protrusion of the shim plate 915 fromthe base 921 (FIG. 9C) of the thermal panel 910. At the time ofinstallation, the installer can select the pair that results in thedesired amount of protrusion. For example, the lowest vertical pair mayresult in shim plate 915 having no protrusion and the thermal panel 910having minimum thickness, while the highest vertical pair results in theshim plate 915 having maximum protrusion and the thermal panel 910having maximum thickness.

FIG. 9E illustrates the frame 935 of the thermal panel 910, with a setof apertures 932 for receiving a fastener inserted through the shimplate 915.

Heat Exchange Systems

One or more embodiments described herein enable the rack assembly 10(FIG. 1) to be used as a heat exchanged, for warming and driving airunderneath the assembly. Numerous types of heat exchange systems may beimplemented with a rack assembly that is configured according to anembodiment described herein. For example, as shown in FIG. 2A, the rackassembly 110 may include both thermal panels (such as described withFIG. 9A-9E) and photovoltaic panels. As an example, while thephotovoltaic panels may by themselves generate sufficient heat to warmair driven under the rack assembly 110, use of thermal panels 910 incombination with photovoltaic panels enables significantly more heat tobe generated, so that even in cold environments, sufficient heat iscreated to warm a dwelling that is tied to a duct system receiving airfrom the channels of the rack assembly.

While embodiments described above contemplate use of the heat to warmducted or channeled air, other embodiments contemplate other uses and/orbenefits for heat generated from the rack assemblies. For example, heatgenerated underneath the rack assembly 110 has the effect of cooling thesolar modules, particularly the photovoltaic modules, and thusincreasing the efficiency of their operations.

FIG. 10A illustrates an implementation in which the rack assembly 110 isprovided over a series of vents 1010. In FIG. 10A, a series of vents1010 is provided extending as a row under a corresponding row of solarmodules 114.

FIG. 10B illustrates an underside of the rack assembly 110, asimplemented in FIG. 10A. The vents 1010 may extend into a ducting system1020 that transports heated air through a dwelling on which the rackassembly 110 is provided. Each vent 1010 may include a duct 1012 thatfeeds one or more main ducts 1015. According to one implementation, anair driver (not shown) such as a fan may draw the air through the ductsystem 1020 and, as such, from under the rack assembly 110.

As mentioned, different channel formations may be provided under therack assembly 110. According to one or more embodiments, the channelsmay be formed by (i) sealed free rail structures 220, (ii) the undersideof individual solar modules 114, and (iii) the underlying body on whichthe rack assembly is mounted. Numerous alternatives are possible, suchas ducted structures that occupy, in whole or in part, open space underthe rack assembly 110.

FIG. 11A shows one configuration in which the plurality of vents 1010are aligned and provided under one row of a solar module array installedwith the rack assembly. Each vent 1010 may draw air from one of theperimeter lengths 1132 that is open. The other perimeter lengths 1134may be closed and sealed over the underlying body. For example, flashingmechanisms, such as described with FIG. 4A and FIG. 8A and FIG. 8B. Theresult may be the formation of a general channel 1120 that extends fromthe open length 1132 to the plurality of vents 1010. In animplementation such as shown, the solar modules 114 are arranged to thatincoming air is warmed by photovoltaic panels 1124, then by thermalpanels 1125 as the air approaches the vents. A fan or other air drivermay be tied or associated with the vent 1010 to draw the air from theopen length 1132.

FIG. 11B shows the formation of an alternative configuration in which amulti-directional channel 1140 is formed below the rack assembly 1120.In an example provided, the open length 1132 may be smaller than theoverall dimension of the perimeter, and the resulting channel 1140 maybend and turn. In a configuration shown, one vent 1010 is provided atthe end of the channel 1140. Air flowing through the channel 1140 passesthrough photovoltaic panels 1124 before reaching the thermal panels1125. In the example provided, the last column of solar modules 114 arethermal panels 1125, for more significant temperature increase to airalready warmed by the photovoltaic panels 1124.

Although the embodiments described above provide a discrete set ofconfigurations and implementations, embodiments of the invention arecapable of a wide range of configurations and applications. While someof these various configurations and applications are discussed belowthey should not be construed as limiting the scope of the invention butas merely providing illustrations of some additional embodiments.

While one or more embodiments described above illustrate a configurationwhere intake air for the array is provided at a lower open edge andrecovered at the sealed upper edge, other configurations are possible.One configuration may consist of a completely sealed perimeter withintake air taken from an internal environment such as the attic or roomsof a building to ventilate such spaces. Alternately, the rack assemblymay be configured with the rail structures oriented laterally with theair intakes positioned on the left, right, or both left and right sides.In a further configuration the array may be configured with theperimeter edges open to uniformly admit intake air. In any of these orother potential configurations the design of the rack assembly is suchthat it allows the air channel under the array to be flexibly arrangedthrough selective sealing of the perimeter edges.

Additionally, while an embodiment described above refer to an air driverused to push or pull air through the array, such a device need not beseparate from the array. While a fan is one embodiment of an air driver,natural buoyancy flows created by the solar modules 114 is also aneffective air driver. This buoyancy driven flow may be created by theheat the solar modules 114 provide to the air channels underneath thearray. Such a configuration of an air driver allows the array topassively ventilate and may be useful in certain embodiments of theinvention.

Although some embodiments described above generally refer to the thermalenergy generated by the solar modules 114 as heat, this should beinterpreted in the general thermodynamic sense as the transfer ofthermal energy from the modules. While the array is receiving solarenergy, there will be a positive transfer of heat from the solar modules114 to the air flowing through the channels behind the array resultingin an increase in the air temperature. This higher temperature air canthen be used for several uses ranging from heating a building space tocrop or lumber drying. When the array is receiving little to no solarenergy there may be negative heat transfer from the modules to the airflowing through the channels behind the array resulting in a decrease inair temperature. This lower temperature air can have several usesincluding flushing a building with cool ventilation air during a summerevening. Depending on the incident solar energy and ambient conditionsthe solar modules may be capable of increasing or decreasing the airtemperature in the channel to provide both heating and coolingcapabilities.

Additionally, while one or more embodiments described above generallyrefer to a construction of the rack assembly attached to a sub structurethrough fasteners, adhesives, or other positive means, otherconfigurations are possible. In one possible embodiment the rackassembly is ballast mounted to the underlying body without positivemeans. Ballast mounting relies on a combination of friction and gravityforces to keep the rack assembly from separating or shifting along theunderlying body. While not practicable in all configurations, themonolithic rack assembly achieved by the linkage of the rail assembliesby the strut runners provides an ideal rack assembly for ballastmounting.

Although an embodiment of the thermal insert described above consists ofa single thermal absorber in contact with the air channel, otherconfigurations are possible. One such configuration would consist of asecondary absorber suspended below the primary absorber described above.This secondary absorber provides an additional heat transfer surfacethat is in convective and radiative communication with the primaryabsorber and enhances the transfer of thermal energy from theabsorber(s) to the air channel. This secondary absorber may take theform of a solid sheet, a perforated sheet, mesh or other suitablesurface. Other configurations employing multiple secondary absorbers invarious forms is also possible.

While an embodiments described above generally refer to a specificarrangement of the array employing a mix of both photovoltaic modulesand thermal modules, other configurations are possible. One suchconfiguration would be where the design goal of the array is solely thegeneration of thermal and not electrical energy. In such a case the rackassembly may consist entirely of thermal modules. Alternately, thedesign goal may be primarily for electrical energy with thermal energyas a by product. In such a case the rack assembly may consist entirelyof photovoltaic modules. The design of the rack assembly enables avariety of configurations for both module styles and can be configuredto suit a wide range of electrical and thermal outputs.

CONCLUSION

Although the descriptions above contain many specifics, these should notbe construed as limiting the scope of the invention but as merelyproviding illustrations of some embodiments.

1. A rack assembly for mounting solar modules over an underlying body,the rack assembly comprising: a plurality of rail structures that arearrangeable over the underlying body to form an overall perimeter forthe rack assembly; one or more retention structures provided with theplurality of rail structures, wherein the retention structures areconfigured to support one or more solar modules at a given height abovethe underlying body; and one or more channels underneath the solarmodules that guide air flow; one or more strut runners that extenddirectly over the underlying body and support the plurality of railstructures; wherein at least some of the plurality of rail structuresare adapted to enable individual rail structures in the plurality ofrail structures to be sealed over the underlying body so as to guide airflow underneath the one or more solar modules; and wherein at least oneof (i) one or more of the rail structures, or (ii) the one or moreretention structures are adjustable so as to adapt the rack assembly toaccommodate solar modules of varying forms or dimensions; and whereinthe one or more channels are multi-directional, so as to each includeone or more bends or turns that guide air flow in both vertical andhorizontal directions under the solar modules.
 2. The rack assembly ofclaim 1, further comprising one or more coupling structures, whereineach of the one or more coupling structures enables at least a portionof one or more of the rail structures to be sealed over the underlyingbody.
 3. The rack assembly of claim 1, further comprising a combinationof coupling structures provided on or with an individual rail structureto enable those rail structures to be sealed over the underlying body.4. The rack assembly of claim 3, wherein the combination of couplingstructures includes an underlying flashing component that extends fromeach of the individual rail structure into or against the underlyingbody.
 5. The rack assembly of claim 4, wherein the combination ofcoupling structures includes an overlaying flashing component thatextends from each of the individual rail structures over the underlyingflashing component.
 6. The rack assembly of claim 1, wherein at leastone of (i) the one or more rail structures, or (ii) the one or morestrut runners are adjustable when mounted onto the underlying body so asto enable the rack assembly to be flexibly fitted onto the underlyingbody.
 7. The rack assembly of claim 1, further comprising a compressionmechanism that is manipulated to compress the retention structures inorder to cause the retention structures to grip a corresponding solarmodule and to provide the corresponding module in a fixed position.
 8. Arack assembly for mounting solar modules over an underlying body,wherein the rack assembly is installed over an underlying body andcomprises: a plurality of rail structures that are arranged to form anoverall perimeter for the rack assembly; and one or more retentionstructures provided with the plurality of rail structures to support oneor more solar modules mounted thereon at a given height over theunderlying body; one or more strut runners that extend directly over theunderlying body and support the plurality of rail structures; wherein atleast some of the plurality of rail structures are sealed over theunderlying body so that at least a portion of the overall perimeter issealed over the underlying body; and a channel that guides air flow, thechannel being formed at least in part by the at least some of theportion of the overall perimeter that is sealed over the underlying bodyand occupies at least a portion of the given height separating the oneor more solar modules from the underlying structure; and wherein thechannel is multi-directional, so as to include one or more bends orturns that guide air flow in both vertical and horizontal directionsunder the solar modules and above the underlying body.
 9. The rackassembly of claim 8, wherein, the channel is formed at least in part byat least some of the plurality of rail structures that are sealed overthe underlying body, and wherein an opening of the channel is orientedto be provided by a remaining portion of the overall perimeter and isopen to permit the exchange of air with an environment of the rackassembly; and wherein the channel is oriented to have one or moreopenings to receive airflow entering from at least one or more segmentsof the remaining portion of the overall perimeter that is open.
 10. Therack assembly of claim 8, wherein at least one of (i) one or more of therail structures, or (ii) the one or more retention structures areadjustable so as to adapt the rack assembly to accommodate solar modulesof varying forms or dimensions.
 11. The rack assembly of claim 7,further comprising one or more sealing features provided with theplurality of rail structures, wherein the one or more sealing featuresenable the individual rail structure to be sealed over the underlyingbody to guide airflow so as to form at least a portion of the channel.12. The rack assembly of claim 10, wherein the one or more sealingfeatures for a given rail structure in the plurality of rail structuresincludes an underlying flashing component that extends into or againstthe underlying body.
 13. The rack assembly of claim 12, wherein the oneor more sealing features for the given rail structure in the pluralityof rail structures includes an overlaying flashing component thatextends over the underlying flashing component.
 14. The rack assembly ofclaim 8, wherein at least one of (i) the one or more rail structures, or(ii) the one or more strut runners are adjustable when mounted onto theunderlying body so as to enable the rack assembly to be flexibly fittedonto the underlying body.
 15. The rack assembly of claim 8, wherein theoverall perimeter is rectangular, and wherein the portion of the overallperimeter is sealed with the underlying body includes a majority ofthree lengths of the rectangle, and wherein the remaining portion of theoverall perimeter that is open to permit the exchange of air with theenvironment corresponds to at least a portion of the remaining length ofthe rectangle.
 16. The rack assembly of claim 8, further comprising acompression mechanism that is manipulated to compress the retentionstructures in order to cause the retention structures to grip acorresponding solar module and to provide the corresponding module in afixed position.
 17. The rack assembly of claim 16, wherein one or moreof the plurality of rail structures include an interior surface fromwhich one or more corresponding retention structures are provided, andwherein each of the one or more rail structures is provided a shim plateon an exterior surface that forms the portion of the overall perimeterso as to support that rail structure when compressed by the compressionmechanism.
 18. A solar energy transfer system provided over anunderlying body, the system comprising: a plurality of solar modulesthat receive solar energy and convert the solar energy into one or moreof (i) electricity, or (ii) heat, wherein the plurality of solar moduleshave a given size that is within a range of possible sizes; a rackassembly that supports the plurality of solar modules a given heightover an underlying body, and one or more channels underneath the solarmodules that guide air flow between the solar modules and the underlyingbody; wherein the rack assembly is sealed across at least a portion ofits perimeter to the underlying body to define, at least in part, one ormore channels underneath the plurality of solar modules that guides airflow; wherein the rack assembly is cooperatively positioned with an airdriver to enable the air driver to direct air through the one or morechannels so that the air is heated by heat from one or more of theplurality of solar modules; wherein the one or more channels aremulti-directional, so as to each include one or more bends or turns thatguide air flow in both vertical and horizontal directions between thesolar modules and the underlying body and wherein the rack assemblyincludes: two or more rail structures rail extending primarily in afirst direction, wherein each of the two or more rail structures thatform part of the perimeter of the rack assembly is sealed over theunderlying body to define at least a part of one or more of thechannels; and one or more end caps that position to seal each of the oneor more channels formed in part by the two or more rail structures. 19.The system of claim 18, wherein the rack assembly is unsealed at one ormore perimeter lengths, and wherein the rack assembly is cooperativelypositioned with the air driver to enable the air driver to intakeenvironment air from at least one of perimeter lengths, and to whereinthe rack assembly is sufficient relative in dimension to heat output ofthe plurality of solar modules to enable the air to be heated from whenit is received at the at least one of the perimeter lengths to when theair is forced inward into or towards the underlying body.
 20. The systemof claim 18, wherein the rack assembly is configured to be adjustablewhen mounted onto the underlying body to support any given solar modulesof a size with the range of possible sizes.
 21. The system of claim 20,wherein the rack assembly includes a combination of flashing structuresto seal the rack assembly over the underlying body.
 22. The system ofclaim 21, wherein the combination of flashing structures includes anunderlying flashing component that extends into or against theunderlying body.
 23. The system of claim 22, wherein the combination offlashing structures includes an overlaying flashing component thatextends over the underlying flashing component.
 24. The system of claim20, wherein the rack assembly includes a plurality of interconnectedrail structures, and wherein each rail structure includes one or moreretention structures to support a corresponding one of the plurality ofsolar modules at the given height above the underlying structure. 25.The system of claim 23, where the rack assembly is adjustable to supportthe any given solar modules of the size with the range of possible sizesin part by at least one of (i) a vertical position or (ii) a graspthickness of the one or more retention structures being adjustable. 26.The system of claim 18, wherein one or more of the plurality of solarmodules corresponds to a thermal panel for directly converting solarenergy to heat.
 27. The system of claim 26, wherein each of the one ormore thermal panels includes a translucent material, an absorptionlayer, and a frame for containing at least the translucent material. 28.The system of claim 27, wherein an effective thickness of at least oneof the one or more thermal panels is adjustable.
 29. The system of claim27, wherein at least one of the thermal panels includes a shim platethat is adjustably mountable to the frame to adjust an overall thicknessof that thermal panel.
 30. A rack assembly for mounting solar modulesover an underlying body, wherein the rack assembly comprising: aplurality of rail structures; and a plurality of retention structuresprovided by the plurality of rail structures, wherein between pairs ofadjacent rail structures in the plurality of rail structures, one ormore of the plurality of retention structures are adjustable to (i)loosely grasp and hold a given solar module to enable manual adjustmentof the positioning and securement of the given solar module, (ii)mechanically secure and hold the given solar module in an installedposition a given height over the underlying body; one or more channelsunderneath the solar modules that guide air flow; wherein the one ormore channels are multi-directional, so as to each include one or morebends or turns that guide air flow in both vertical and horizontaldirections under the solar modules; and wherein the plurality of railstructures include a plurality of free edge rail structures that form aperimeter of the rack assembly, and wherein at least the plurality offree edge rail structures include coupling structures to seal those railstructures over the underlying body; wherein the one or more of theplurality of retention structures include a mechanical coupling thatmechanically secures and holds the given solar module in the installedposition; wherein the one or more of the plurality of retentionstructures corresponds to a top ledge moveably coupled to a bottom ledgeto move between an extended engagement position and a contractedengagement position, and wherein the mechanical coupling can bemanipulated to direct the top ledge and the bottom ledge between theextended and contracted engaged position.
 31. The rack assembly of claim30, further comprising one or more strut runners that extend across theunderlying body and support the plurality of rail structures.
 32. Therack assembly of claim 30, wherein each of the plurality of railstructure is formed by at least a top segment and a bottom segment, andwherein at least the top ledge of the one or more of the plurality ofretention structures is formed on the top segment.
 33. The rack assemblyof claim 32, wherein: each of the one or more of the plurality of railstructure is formed by at least a top segment and a bottom segment, andwherein at least the top ledge of the one or more of the plurality ofretention structures is formed on the top segment, and wherein themechanical coupling includes a member extending vertically into one ormore of the rail structures; and wherein the rack assembly furthercomprises one or more strut runners provided between the underlying bodyand individual rail structure, and wherein the member of the mechanicalcoupling extends within each of the one or more of the rail structures.34. A solar module for a rack assembly that supports an array of solarmodules, the solar module comprising: a translucent material; anabsorption layer provided underneath the translucent material to absorbsolar energy passing through the translucent material; and a frame thatcontains the translucent material and the absorption layer, the frameincluding one or more surfaces that can be retained by retentionstructures of the rack assembly; and wherein the frame is adjustable tovary its thickness in order to facilitate its retention by the retentionstructures; and one or more channels underneath the array of solarmodules that guide air flow; and wherein the one or more channels aremulti-directional, so as to each include one or more bends or turns thatguide air flow in both vertical and horizontal directions under thearray of solar modules; and a shim plate for the frame, wherein at leastone of the shim plate and the retention structure is configured toenable a position of the shim plate to be varied when mounted to theframe, wherein the position of the shim plate determines the thicknessof the frame.
 35. A rack assembly for mounting solar modules over anunderlying body, the rack assembly comprising: a plurality of railstructures that are arrangeable over the underlying body to form anoverall perimeter for the rack assembly; one or more retentionstructures provided with the plurality of rail structures, wherein theretention structures are configured to support one or more solar modulesat a given height above the underlying body; and one or more channelsunderneath the solar modules that guide air flow; a compressionmechanism that is manipulated to compress the retention structures inorder to cause the retention structures to grip a corresponding solarmodule and to provide the corresponding module in a fixed position; andwherein at least some of the plurality of rail structures are adapted toenable individual rail structures in the plurality of rail structures tobe sealed over the underlying body so as to guide air flow underneaththe one or more solar modules; and wherein at least one of (i) one ormore of the rail structures, or (ii) the one or more retentionstructures are adjustable so as to adapt the rack assembly toaccommodate solar modules of varying forms or dimensions; and whereinthe one or more channels are multi-directional, so as to each includeone or more bends or turns that guide air flow in both vertical andhorizontal directions under the solar modules.
 36. The rack assembly ofclaim 35, further comprising one or more coupling structures, whereineach of the one or more coupling structures enables at least a portionof one or more of the rail structures to be sealed over the underlyingbody.
 37. The rack assembly of claim 35, further comprising acombination of coupling structures provided on or with an individualrail structure to enable those rail structures to be sealed over theunderlying body.
 38. The rack assembly of claim 35, wherein thecombination of coupling structures includes an underlying flashingcomponent that extends from each of the individual rail structure intoor against the underlying body.
 39. The rack assembly of claim 38,wherein the combination of coupling structures includes an overlayingflashing component that extends from each of the individual railstructures over the underlying flashing component.
 40. The rack assemblyof claim 35, wherein at least one of (i) the one or more railstructures, or (ii) the one or more strut runners are adjustable whenmounted onto the underlying body so as to enable the rack assembly to beflexibly fitted onto the underlying body.